Chapter 4 – Manual Assembly Lines: Full MCQ Bank
1. Which of the following best defines a manual assembly line?
A) A robotic automated line with no human labor
B) A sequence of workstations where humans perform assembly tasks
C) A batch manufacturing system
D) A flexible manufacturing cell
Correct Answer: B
Explanation: Because a manual assembly line involves multiple human workers performing
tasks at stations along the line.
2. Which condition MOST favors using assembly lines?
A) Very small demand and high product variety
B) High/medium demand and similar products
C) Products differing significantly requiring setups
D) Products that cannot be divided into elements
Correct Answer: B
Explanation: Assembly lines are profitable when demand is high and tasks can be divided
into elements.
3. Why are assembly lines productive?
A) Workers perform random tasks
B) Learning curve & specialization
C) Products move slowly
D) Cycle time is unlimited
Correct Answer: B
Explanation: Specialization and learning effects greatly improve productivity.
4. What is cycle time (Tc)?
A) Time to build one unit from start to finish
B) Time between completed units leaving the line
C) Break time for operators
D) Actual working time per shift
Correct Answer: B
Explanation: Cycle time is the spacing between consecutive unit completions.
5. What does 'starving' mean in assembly lines?
A) Operator refuses to work
B) Downstream station waiting for parts
C) Parts accumulate excessively
D) Cycle time decreases
Correct Answer: B
Explanation: Starving occurs when a station waits because previous station has no output.
6. What is the theoretical minimum number of workers (w*)?
A) Tc / Twc
B) Twc / Tc
C) Twc × Tc
D) Tc – Twc
Correct Answer: B
Explanation: Minimum workers = total work content / cycle time.
7. Which of the following is a reason the theoretical minimum cannot be achieved?
A) Perfect line balance
B) Excess automation
C) Repositioning losses
D) Zero variability
Correct Answer: C
Explanation: Repositioning time reduces available service time, making ideal minimum
impossible.
8. Repositioning efficiency Er equals:
A) Ts/Tc
B) Tr/Tc
C) Tc - Ts
D) Twc/Ts
Correct Answer: A
Explanation: Repositioning efficiency measures usable time relative to cycle time.
9. Line balancing aims to:
A) Maximize idle time
B) Assign equal work across stations
C) Increase number of workers
D) Remove precedence rules
Correct Answer: B
Explanation: Goal is fairness and efficiency by equal workload distribution.
10. Ranked Positional Weight (RPW) is:
A) Average of element times
B) Tek only
C) Sum of Tek and all successors
D) Random ranking
Correct Answer: C
Explanation: RPW includes task time plus successors' time.
Chapter 8 – Methods Engineering & Data Tools: Full MCQ Bank
1. What is the main objective of methods engineering?
A) Increase cost
B) Increase cycle time
C) Increase productivity
D) Increase waiting time
Correct Answer: C
Explanation: Methods engineering improves productivity, efficiency, and reduces waste.
2. Methods analysis deals with:
A) Creating new products
B) Studying existing methods to improve them
C) Marketing issues
D) Financial auditing
Correct Answer: B
Explanation: It examines current methods for optimization.
3. Which is the FIRST step in systematic approach?
A) Implement solution
B) Define the problem
C) Audit study
D) Form alternatives
Correct Answer: B
Explanation: A problem must be defined before analysis.
4. Which tool shows frequency distribution?
A) Check sheet
B) Histogram
C) Scatter diagram
D) Pareto cumulative
Correct Answer: B
Explanation: Histograms show distribution and shape of the data.
5. Pareto principle states:
A) 50% of issues come from 50% causes
B) 80% of effects come from 20% causes
C) 20% issues = 20% causes
D) No relationship exists
Correct Answer: B
Explanation: The 80-20 rule is the foundation of Pareto analysis.
6. Check sheet is used for:
A) Data collection
B) Regression analysis
C) Line balancing
D) Cost estimating
Correct Answer: A
Explanation: Check sheets help gather raw data quickly and visually.
7. Scatter diagram is useful for:
A) Showing average cost
B) Identifying correlation between variables
C) Showing percentages
D) Tracking sequence of operations
Correct Answer: B
Explanation: It shows possible relationships between two variables.
8. Cause and Effect (Fishbone) diagram includes:
A) Marketing, sales, customers, profit
B) Machines, materials, methods, people
C) Cycle time, work content, efficiency
D) Transportation, layout, distance
Correct Answer: B
Explanation: Fishbone identifies major sources of problems.
